Presentation onSafety Best Practices in

“The Ramco Cements Limited”R.R. Nagar Unit

ISO 9001ISO 14001 &

IS 18001

Presentation onSafety Best Practices in

“The Ramco Cements Limited”R.R. Nagar Unit

National conclave on Recent advances in Cement Industry ,21st October, 2016 at HICC, Hyderabad

RR NAGAR Plant ViewRR NAGAR Plant View

Company OverviewCompany OverviewFlagship Company & Brand of the Ramco GroupThe Ramco Cements Limited is the flagship company of the Ramco Group, a well-known business group of SouthIndia. It is headquartered at Chennai. The main product of the company is Portland cement, manufactured in eightstate-of-the art production facilities that includes Integrated Cement plants and Grinding units with a current totalproduction capacity of 16.45 MTPA (out of which Satellite Grinding units capacity alone is 4 MTPA). The company isthe fifth largest cement producer in the country. is the most popular cement brand in South India.The company also produces Ready Mix Concrete and Dry Mortar products, and operates one of the largest wind farmsin the country.Integrated Cement PlantsRamasamy Raja Nagar, Virudhunagar District, Tamil Nadu (Mother Plant started operations @ 1962)Alathiyur, Ariyalur District, Tamil NaduAriyalur, Govindapuram, Ariyalur District, Tamil NaduJayanthipuram,Krishna District, Andhra PradeshMathodu, Chitradurga District, KarnatakaGrinding Units•Uthiramerur, Kanchipuram District, Tamil Nadu•Valapady, Salem District, Tamil Nadu•Kolaghat, Purba Medinipur District, West Bengal•Vizag, Visakhapatnam , Andhra PradeshPacking Terminals•Nagercoil Packing Unit, Kumarapuram, Aralvaimozhi, Kanyakumari District, Tamil NaduState-of-the-Art Research Centre•Ramco Research Development Centre (RRDC), Chennai Page 3

Company OverviewFlagship Company & Brand of the Ramco GroupThe Ramco Cements Limited is the flagship company of the Ramco Group, a well-known business group of SouthIndia. It is headquartered at Chennai. The main product of the company is Portland cement, manufactured in eightstate-of-the art production facilities that includes Integrated Cement plants and Grinding units with a current totalproduction capacity of 16.45 MTPA (out of which Satellite Grinding units capacity alone is 4 MTPA). The company isthe fifth largest cement producer in the country. is the most popular cement brand in South India.The company also produces Ready Mix Concrete and Dry Mortar products, and operates one of the largest wind farmsin the country.Integrated Cement PlantsRamasamy Raja Nagar, Virudhunagar District, Tamil Nadu (Mother Plant started operations @ 1962)Alathiyur, Ariyalur District, Tamil NaduAriyalur, Govindapuram, Ariyalur District, Tamil NaduJayanthipuram,Krishna District, Andhra PradeshMathodu, Chitradurga District, KarnatakaGrinding Units•Uthiramerur, Kanchipuram District, Tamil Nadu•Valapady, Salem District, Tamil Nadu•Kolaghat, Purba Medinipur District, West Bengal•Vizag, Visakhapatnam , Andhra PradeshPacking Terminals•Nagercoil Packing Unit, Kumarapuram, Aralvaimozhi, Kanyakumari District, Tamil NaduState-of-the-Art Research Centre•Ramco Research Development Centre (RRDC), Chennai

Safety Department Objectives Achieving ‘Zero Injuries/Incidents’. To attain accident free man hours. Emergency Preparedness & Response and Planning. To promote and improve the Safety and Health awareness of company

employees & contract workmen. To strengthen safety movement and drive the culture from top to

bottom level as the safety is each and every one’s responsibility. The safe execution of activities in all areas with IMS Policy and to

comply with statutory provisions. We adopting 4E’s technique to ensure safety among all by following

i) Engineeringii) Educationiii) Encouragement andiv) Enforcement

Achieving ‘Zero Injuries/Incidents’. To attain accident free man hours. Emergency Preparedness & Response and Planning. To promote and improve the Safety and Health awareness of company

employees & contract workmen. To strengthen safety movement and drive the culture from top to

bottom level as the safety is each and every one’s responsibility. The safe execution of activities in all areas with IMS Policy and to

comply with statutory provisions. We adopting 4E’s technique to ensure safety among all by following

i) Engineeringii) Educationiii) Encouragement andiv) Enforcement

Company Organization Chart &Safety Organization Chart

PRESIDENTPRESIDENTMFGMFG

Sr.GMSr.GMWORKSWORKS

Company Organization Chart Safety Organization Chart

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SMSMSafetySafety

DMDMSafetySafety

Regular Activities Safety Oath and Speech-Every Monday for all contract workmen PEP Talk – Every week PEP talk for permanent and contract Workmen Work Permit / Electrical line clearance and LOTO system. Awareness Training for employees including contractors Safety Discussion-Daily Unsafe Act and Conditions discussion at

Production Meeting and every week Safety presentation on unsafe actand conditions & tunnel conditions.

Painting of Safety Awareness Posters and paintings throughout plant . Identification of Unsafe Act and condition- If any unsafe act/condition

identified, the mail information given to respective sectionincharge/departments /HODs to rectify the same (along with Photos).

Safety committee and Safety co-ordinators meeting once in a month.

Safety Oath and Speech-Every Monday for all contract workmen PEP Talk – Every week PEP talk for permanent and contract Workmen Work Permit / Electrical line clearance and LOTO system. Awareness Training for employees including contractors Safety Discussion-Daily Unsafe Act and Conditions discussion at

Production Meeting and every week Safety presentation on unsafe actand conditions & tunnel conditions.

Painting of Safety Awareness Posters and paintings throughout plant . Identification of Unsafe Act and condition- If any unsafe act/condition

identified, the mail information given to respective sectionincharge/departments /HODs to rectify the same (along with Photos).

Safety committee and Safety co-ordinators meeting once in a month.

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Safety Corner (Monthly) : Display of Safety related news and issues Fire drill for security by fire advisor Internal & External safety training for Engineers & Workmen Emergency evacuation ( Mock drill ) /Fire drill conduction. Incident/Accident reporting & Investigation Conducts RCA on all incidents such as property damage, Loss of product,

H&S related. And formulates Preventive action plan. Safety Awareness through Voice message is implemented through PA

system Safety Awareness through Voice message (Tamil/Hindi) is implemented at

Morning Prayer from 7.50 am to 8.00 am daily. Motivating employees for following best safety standards Safety speech by employees every month.

Regular Activities

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Safety Corner (Monthly) : Display of Safety related news and issues Fire drill for security by fire advisor Internal & External safety training for Engineers & Workmen Emergency evacuation ( Mock drill ) /Fire drill conduction. Incident/Accident reporting & Investigation Conducts RCA on all incidents such as property damage, Loss of product,

H&S related. And formulates Preventive action plan. Safety Awareness through Voice message is implemented through PA

system Safety Awareness through Voice message (Tamil/Hindi) is implemented at

Morning Prayer from 7.50 am to 8.00 am daily. Motivating employees for following best safety standards Safety speech by employees every month.

Fixed Life line rope for mills and Kilns, bulker sealingSafety pouches for all employees. Our plant was IS 18001:2007 certified, hence for all critical maintenance

Works HIRA have been conducted and readily made available at ISO system. Standard operating procedures make available for critical and regular activities. Reflective jackets for all employee and contractors .Heat resistance suit (Kevlar) for coating and cyclone jam

cleaning at pre-heater. Belt conveyor Tail end guard belt drum to 1st carrying idler and counter weight

guardFire hydrant system for entire plant & fire sprinkler system for bag storage go down.Low pressure blower for body cleaning .LHS Cable for Coal Conveyor Belt.Height pass (Authorization card) system for persons working at height more

than 2.5 mtrs.Safety Help Desk systemColor coding systems for helmet, reflective jackets.

Best Safety Practices implemented

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Fixed Life line rope for mills and Kilns, bulker sealingSafety pouches for all employees. Our plant was IS 18001:2007 certified, hence for all critical maintenance

Works HIRA have been conducted and readily made available at ISO system. Standard operating procedures make available for critical and regular activities. Reflective jackets for all employee and contractors .Heat resistance suit (Kevlar) for coating and cyclone jam

cleaning at pre-heater. Belt conveyor Tail end guard belt drum to 1st carrying idler and counter weight

guardFire hydrant system for entire plant & fire sprinkler system for bag storage go down.Low pressure blower for body cleaning .LHS Cable for Coal Conveyor Belt.Height pass (Authorization card) system for persons working at height more

than 2.5 mtrs.Safety Help Desk systemColor coding systems for helmet, reflective jackets.

Workforce & Man hours Worked &Safety Performance

Sl.No. Type of Workers 2014-15 2015-161 Regular 469 4672 Contract 374 367

Total 843 834

Sl.No. Type of Workers 2014-15 2015-161 Regular 469 4672 Contract 374 367

Average no of workers in factory

Man hours worked by all workers including over time worked

FromPeriod

ToPeriod

Noof

Days

Accident FreeMillion Man

Hours

07.10.14 30.01.15 11610,53,976

(1.05 Million)

Accident Free Million Man Hours

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2 Contract 374 367Total 843 834

Type 2014-15 2015-16Near miss Nil 5High Potential Near miss Nil 1First – aid cases 9 6LTI ( Lost Time Incident ) 0 1Fatality Nil NilMan hours lost due to LTI Nil 3600Severity Rate Nil 202.54Frequency Rate Nil 2.25No of Dangerous occurrences as per factory act Nil 1

Safety Performance

Safety Oath and Speech

Every Monday, Safety Oathand Gate safety meeting/PEPtalk for workers.

Everyday, Safety Pledge byCompany employees.

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Every Monday, Safety Oathand Gate safety meeting/PEPtalk for workers.

Everyday, Safety Pledge byCompany employees.

Tool Box Talk• Safety Tool box Talk is being

conducting on each and everyday at all sections of plantpremises.

• Creating awareness on theparticular risky job beforegoing to do that work.

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• Safety Tool box Talk is beingconducting on each and everyday at all sections of plantpremises.

• Creating awareness on theparticular risky job beforegoing to do that work.

Safety flag hoisting, Safety Speech andAwards on Safety Day

Every month first Wednesday, Safety Daycelebrated on this day, safety speech byemployee and safety awards.

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Work permit/Line Clearance

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LOTO System

All electrically connected equipments to ensure that they areproperly isolated for hazardous or potentially hazardous electricalenergy sources during servicing and or maintenance and properlyprotect against re-energization.

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Excavation & height work permit

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Awareness training for Permanent employee andcontractors (Based on Trade wise Safety training matrix)

External Safety training & DefensiveTraining – Drivers

• Safety training to employees byexternal agencies

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Training Particulars & Mock drill

S.No Trainings 2014-15 2015-161 Internal trainings 26 172 External trainings 2 23 Training Participants Company 320 2764 Training Participants Contractors 347 2915 Total Training hours 2722 20426 Training Hr. individual per employee per annum 7.03 5.917 Training Hr. Contractor individual per employee per annum 1.35 1.12

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7 Training Hr. Contractor individual per employee per annum 1.35 1.128 Covered Employees (%) 68.23 59.109 Covered contract workforce 92.78 79.29

S.No Description 2014-15 2015-16

1 Emergency Evacuation Mock Drill with Fire Demo 1 22 Fire Demo 2 23 Fire Hydrant Demo - 2

Height Pass System-Application Form

Height pass issued topersons working atheight more than 2.5meters.

After pre-medicalexamination and safetytraining

Card valid for one year. Persons with valid

height pass was onlyallowed to performheight work.

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Height pass issued topersons working atheight more than 2.5meters.

After pre-medicalexamination and safetytraining

Card valid for one year. Persons with valid

height pass was onlyallowed to performheight work.

Height Pass System- Medical FitnessCertificate & Height Pass Card

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Safety Awareness Paintings andPosters

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Safety help desk (Online) System To strengthen safety among all

Safety help desk online systemwas created.

As every person canreport/record safetyobservations andrequirements such as in thesystem.i) Unsafe actsii) Unsafe conditionsiii) Near missIv) Other incidents

An automated mail will bedelivered to the concerndepartment, Safety Officersand Works Head on daily basisfor continuous follow up ofcompliance.

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To strengthen safety among allSafety help desk online systemwas created.

As every person canreport/record safetyobservations andrequirements such as in thesystem.i) Unsafe actsii) Unsafe conditionsiii) Near missIv) Other incidents

An automated mail will bedelivered to the concerndepartment, Safety Officersand Works Head on daily basisfor continuous follow up ofcompliance.

Safety Help Desk System- Transaction log

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Safety Help Desk System- Report Status

Safety Help Desk System- AutomatedMail

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Safety Committee &Safety Co-ordinators (Mentors)

SAFETY COMMITTEE MEMBERS for the Year 2014 – 2016:Safety committee meeting conduction on 10th of the every month. Safety Committee Chairman – Plant head Safety Committee Secretary – Safety officer Equal participation from Management and workmen:

To identify the hazards and to prepare, implement and monitor the effectiveness of controlmeasures.

To identify the any requirement of specific PPE’s and systems.

SAFETY COMMITTEE MEMBERS for the Year 2014 – 2016:Safety committee meeting conduction on 10th of the every month. Safety Committee Chairman – Plant head Safety Committee Secretary – Safety officer Equal participation from Management and workmen:

To identify the hazards and to prepare, implement and monitor the effectiveness of controlmeasures.

To identify the any requirement of specific PPE’s and systems.

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SAFETY CO-ORDINATORS A representative from each department/section deployed as safety co-ordinators (mentors). Safety co-ordinators meeting conduction on 25th of the every month and MOM preparation &

circulation. After completion of meeting Safety Group (observation)walk to identify unsafe acts, condition and

visual examination of operating parameters. After Completion of safety group walk non-compliance observation report will be to circulated to

concern department for rectification. To educate the co-worker, regarding the safety practice associated with the work. To inform the unsafe activities & unsafe condition to the section – in charges & safety dept. To co-ordinate the safety related function.

Safety Group (Observation) Walk

Safety Group (observation) walk forContinual Improvement by walking aroundthe work place to identify and rectify safetyrelated deficiencies headed by Works Headand Safety officer.

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Implementation of Reflective Jackets

In view of better visibility at the place like tunnels, conveyor andtrench areas & post evening time, we have issued to safetyreflective jackets for our entire company employee’s, contractworkmen, visitors and etc.

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Safety warning & Penalty system-Safety Enforcement

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Safety Audits & Incident/AccidentReport

Sl.No

.Safety Audits

2014-15

2015-16

1 Internal

No ofObservation

310 220

Name of the Person involvedAge of the PersonEmployee Code(If not Employee, Provide the ContactorName)DepartmentDate & Time of Accident Date: Time: pm

Witness ContactNo: EXT -

Accident Location: (Section / Building / If in open Yard Give location in reference tonearest plant/building)

Accident Description (Describe fully the procedure being followed and include allequipments, machineries being used which were related to Accident)

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No ofObservation

Compliance 306 215

Variance 4 5

2 External

No ofObservation

Nil 121

Compliance 80

Variance 40

Accident Description (Describe fully the procedure being followed and include allequipments, machineries being used which were related to Accident)

Site inspection:

Photo

Corrective / Preventive Action:Corrective Action:Preventive Action:

PPE Used at the timeof Accident / NotApplicableSeverity High Medium LowMiscellaneous Information (Provide any other Information orRecommendation which you feel are pertinent to the Accident)Nil.

Accident reporting systemIncident Occurs

@ workplace

Incident spotted by any person-Informs Supervisor

Supervisor- Communicates toArea in charge and Takes

appropriate action

A

Incident isSignificant

processsafety

incident

Plant head appoints investigation committee

Preparation and submission of Investigation report to Plant head

Investigation shall be done by theHOD concerned and two membersof his choosing and Safety officer

YesYes

No

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Supervisor- Communicates toArea in charge and Takes

appropriate action

Area in charge ensuresmitigation of incident and makes

necessary arrangements forproviding medical and to the

injured person

Sectionin

chargesfiles

incidentreportNoticed concerned dept head,

Plant head and Safety headthrough mobile

A

Preparation and submission of Investigation report to Plant head

Circulation of the reviewed report

Reportapproved

Second Review Committee

Plant head shall delegate authority to carry out CA and PA

Plant Head shall review progress of the CA & PA and their status.

Safety Dept shall prepare follow up action report & submit to all on weekly basis.

No

Yes

PPE’S Exhibition Hall

To create safety awareness /PPE to the new joiners andvisitors, Safety PPE ExhibitionRoom is formed.

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Accident-Free Man-Hours LED Display Board

Accident-Free Man-Hoursboard displayed at in front oftime office. For the purpose ofeach and every day Accident-Free Man-Hours to beupdated. Even small First aidinjury also we consider asaccident and mention zerohours in that board.

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Accident-Free Man-Hoursboard displayed at in front oftime office. For the purpose ofeach and every day Accident-Free Man-Hours to beupdated. Even small First aidinjury also we consider asaccident and mention zerohours in that board.

Monthly Safety News Letter

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Displayed @ noticeboards

English Version Tamil Version (Locallanguage)

Fire hydrant system & Linear Heat SensingCable for fire detection system in coal belt

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Life Line with fall arrestor,Safety Guards & low pressure blower for body

cleaning

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Occupational health

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Fire Drill For Fire Fighters And Employees& Emergency Mock Drill

Fire mock drill conducting underguidance of fire advisor for firefighters(securities) and allemployees to create awareness.

Emergency evacuation mockdrill conducting once in 6months. Tamil nadu Fire ServiceDept called for mock drill tocreate fire fighting andevacuation awareness amongall held on 23.12.15 .

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Emergency evacuation mockdrill conducting once in 6months. Tamil nadu Fire ServiceDept called for mock drill tocreate fire fighting andevacuation awareness amongall held on 23.12.15 .

NATIONAL SAFETY WEEK CELEBRATION

SAFETY PROCESSION- RALLY PPE EXHIBITION INAUGURATION

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National Safety Week Celebration- Competitions

SAFETY QUIZ, SPEECH ESSAY WRITING, DRAWING

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National Safety Week CelebrationDOMESTIC SAFETY TRAINING FOR COLONY, SAFETY DRAMA VALEDICTORY FUNCTION- PRIZE DISTRIBUTION

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Thank you for Attention & PleasantListening..

Thank you for Attention & PleasantListening..